Metal structuring system

ABSTRACT

A metal structuring system is disclosed preferably consisting of a plurality of inner wall elements and a plurality of outer wall elements fastened together to form the walls of a building/structure. The system uses the inner and outer metal wall elements as structural ingredients, as well as a cosmetic covering, to provide rigidity and strength, while also providing overall lightness. The attachment of the inner wall and outer wall elements, yields a single, hollow space between the inner and outer walls for the injection of an insulating materials, such as impregnated foam. The inner wall elements and the outer wall elements are preferably similar in shape and construction.

[0001] This application claims the benefit and priority of Provisional Application No. 60/170,966 filed on Dec. 15, 1999.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The invention relates generally to metal structural systems, and, particularly to a metal structural system which uses the inner and outer metal wall elements as structural ingredients to yield a single hollow wall elements capable of being insulated through injection techniques.

[0004] 2. Description of Related Art

[0005] Most metal building systems that are going to be insulated rely on a fabric backed insulation that is cumbersome to install, difficult to join and preferably fill the entire space, thereby increasing its thermal efficiency. Fabric backed insulation generally fails to fill entirely. It is to provide an alternative to these building systems that the present invention is directed.

BRIEF SUMMARY OF THE INVENTION

[0006] The present invention provides a structural system, such as a metal structuring system The system preferably consist of a plurality of inner wall elements and a plurality of outer wall elements fastened together to form the walls of a building/structure. The system uses the inner and outer metal wall elements as structural ingredients, as well as a cosmetic covering, to provide rigidity and strength, while also providing overall lightness, not found with prior art techniques.

[0007] The attachment of the inner wall and outer wall elements, yields a single, hollow space between the inner and outer walls. The walls, as well as the roof of the system, can be insulated through injection of an insulating materials, such as, but not limited to, impregnated foam, throughout the structure. As the insulating material is preferably injected throughout the structure, the insulating material adds to the building/structure's strength. The various elements can preferably be constructed to form the structure, using common hand tools.

[0008] The instant invention will now be described with particular reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0009]FIG. 1 is a top perspective cutaway view of a metal structuring system in accordance with the present invention;

[0010]FIG. 2 is a top perspective view of a corner of the metal structuring system of FIG. 1;

[0011]FIG. 3 is a top perspective view of the metal structuring system of FIG. 1 with a track member partially cutaway;

[0012]FIG. 4 is a top view of certain elements of the metal structuring system of FIG. 1;

[0013]FIG. 5 is a top and top exploded view of a corner area of the metal structuring system of FIG. 1;

[0014]FIG. 6 is a top view of a corner area of the metal structuring system of FIG. 1;

[0015]FIG. 7 is a perspective view of a trim for use with the metal structuring system of FIG. 1;

[0016]FIG. 7-A is a perspective view of a window for use with the metal structuring system of FIG. 1;

[0017]FIG. 8 are perspective cutaway views of a base mold for use with the metal structuring system of FIG. 1;

[0018]FIG. 9 is a perspective cutaway view of the base mold disposed at the corner of the metal structuring system of FIG. 1;

[0019]FIG. 10 is perspective view of the metal structuring system in commercial application with use of an electrical conduit; and

[0020]FIG. 11 is a side sectional view of an embodiment of the metal structuring system shown attached to a conventional roof.

[0021]FIG. 12 is a side sectional view of an embodiment of the metal structuring system shown attached to a conventional foundation.

DETAILED DESCRIPTION OF THE INVENTION

[0022] As seen in the drawings a structural system, such as a metal structuring system, is illustrated and generally designated system 10. System 10 preferably consist of a plurality of inner wall elements 12 and a plurality of outer wall elements 14 fastened together to form the walls of a building/structure, refrigerated structure, etc. System 10 uses inner and outer metal wall elements 12 and 14, respectively, as structural ingredients, as well as a cosmetic covering, to provide rigidity and strength, not found with prior art techniques.

[0023] The attachment of the inner wall and outer wall elements, described below, yields a single, hollow space 16 between the inner and outer walls, 12 and 14, respectively. Walls 12 and 14, as well as the roof of the system, can be insulated through injection of an insulating materials, such as, but not limited to, impregnated foam, throughout the structure. As the insulating material is preferably injected throughout the structure, the insulating material adds to the building/structure's strength. The various elements can preferably be constructed to form the structure, using common hand tools. The various figures illustrate different aspects of the present invention system and will be discussed in further detail below.

[0024]FIG. 1 illustrates a joint 20 for the structural system 10, which is the actual structural component of system 10. Joint 20 preferably provides stud like element, shown in FIG. 1 to be part of the inside wall 12, preferably with two neoprene gaskets 30 and 32. Gasket 30 is preferably a weather gasket, while gasket 32 is preferably a thermal break gasket. Gaskets 30 and 32 inhibit material flow from the inside of the building to the outside, thus, optimizing the thermal advantage of the insulating materials, such as foam, that is injected once the structure is formed. Screws 45, or other fastening devices, are the main fastener connecting the two pieces (either wall 12 to wall 14, wall 14 to wall 14, and/or wall 12 to wall 12) together to form joint 20. Inner screws 45 are inserted through apertures 41, 33 and 38, while outer screws 47 are inserted through apertures 39, 35 and 49.

[0025]FIG. 1 and 3 also illustrate the stud portion (u-shaped end 42 or 80) of the wall, which is structural, and separates the inside wall 12 from the outside wall 14. As shown in FIG. 3, the u-shaped end may be a part of the inside wall 12 or the outside wall 14, depending upon the orientation of the wall elements in the construction of the system 10. One or more holes 36 is (are) preferably provided at U-shaped end 24 or 80. Hole 36 allows insulating material such as foam to freely flow between chambers 16 and gives the otherwise chambered or separated insulating material a connection with each other. The assembled structure, once filled with foam, is relatively rigid. The foam positioned against the inner surfaces of both walls 12 and 14 provides a relatively strong component to the structure, helping to prevent the structure from being unintentionally deformed. Screws 45 and 47 preferably hold the walls together. Where walls 12 and 14 are constructed from aluminum, screws 45 and 47 are preferably constructed from stainless steel to help prevent a galvanic reaction or a bimetal reaction which could promote corrosion.

[0026] Screws 45 and 47, as well as other screws and/or fastening members of the invention, can also be coated with a resin or a glue on their threaded part, which preferably heats up as they are driven into metal walls 12 and/or 14, due to friction. The glue then activates, causing the screws to be glued in, to help accidental dislodging of the screws. Preferably, screws 45 and 47 are placed frequently, i.e. 4 to 6 inches along the entire run. System 10 can also be scaled also to produce boxes, such as refrigerated boxes for tractor trailers. Once the structure is assembled and filled with foam, the foam also acts as a type of glue to also hold the structure together, making it a relatively rigid system and relatively resistant to wind loading. System 10 allows the insulation to be absolute and a great R factor. System 10 lends itself to mobile applications, as well as for office recreational trailers, cargo containments, containers where insulating is important such as for the shipping of produce and other temperature sensitive commodities, etc. System 10 can also be riveted together rather than screwed together.

[0027]FIGS. 2, 5 and 6 illustrate a preferred corner 100 for metal structuring system 10. Corner 100 is preferably built up in order to make the system flow from one section to the next. Walls 12 come together at adjacent ends 13 to form the inner corner 15. Walls 12 are connected in accordance with the present invention. Particularly, walls 12 are preferably attached by fastening members 45, such as screws, which are inserted through walls 12, gaskets 30, and side walls 86 of U-shaped ends 80 of outer walls 14.

[0028] Gaskets 32 are disposed between side walls 84 of U-shaped ends 80 and a inner corner piece 101. Gaskets 30 and 32 can be preinstalled. An additional gasket 104 is preferably provided and disposed between inner corner piece 101 and an outer corner piece 102. Preferably, outside corner piece 102 is constructed from a heavier gauge metal than the other components of system 10. Corner pieces 101 and 102 are attached through fastening members 47, such as screws, which are inserted through corner piece 102, gasket 104, corner piece 101, gaskets 32, and side walls 84 of U-shaped ends 80 of outer walls 14. Outer corner piece 102 protects corner 100 in an industrial environment where it is common for structuring system 10 to be struck by objects. Corner piece 102 also helps to provide an attractive appearance for corner 100.

[0029]FIG. 3 illustrates the attachment of inner walls 12 to outer walls 14 and also shows a track like member 90 formed on the top of walls 12 and 14 for attachment of a top member 110. Top member 110 is preferably provided with holes 112 for filling the insulating material, such as foam, into the hollow chambers 16 defined between walls 12 and 14, after the structure 10 is complete. As seen in FIG. 3, side wall 42 of inner wall 12, as well as side wall 82 of outer wall 14, can be provided with apertures 36 to allow the insulating material injected in the various chambers 16 to bond together. Caps or plugs 114 can be provided for plugging holes 112 once the foam has been injected.

[0030]FIG. 4 shows the main pieces of structuring system 10, namely inner wall 12 and outer wall 14, and specific inner wall 12 having end 13, for use in forming corner 100. The corner is illustrated in FIGS. 2, 5 & 6. As shown in FIG. 4, inner wall 12 and outer wall 14 can be constructed to be similar to each other, and provide the inside skin and the outside skin of the structure 10. When flipped end to end, walls 12 and 14 couple, as shown in the drawings.

[0031]FIGS. 7 and 7-A show a trim 150 which can be disposed in openings or penetrations through walls 12 and 14 of building structure 10. Trim 150 preferably consist of two pieces 152 and 154. Trim 150 can house an air conditioning unit, window to allow outside light, etc. To install trim 150, a hole is cut in walls 12 and 14 of structure 10 by conventional means such as a saber saw hand tool or the like. Once the holes in wall 12 and 14 are cut, either piece 152 or 154 is slid in the hole of wall 12 and from inside structure 10 and the other piece 154 or 152 is slid in the hole of wall 14 from outside the structure. Once pieces 152 and 154 are properly inserted within the holes, they are preferably clamped together and then fastened to each other, by a fastening member such as screws 156 to provide a trimmed out opening in building structure 10. When properly inserted, borders 158 and 159 of trim 150 abut or are disposed flush against walls 12 and 14. System 10, with trim 150, can be used for industrial applications, for use with either large buildings and/or office trailer applications, and provides good thermal resistance from the prevailing temperatures—either hot or cold, as well as being easy to air condition and/or heat.

[0032]FIG. 7-A illustrates an embodiment wherein wall elements are fit together to add windows. In addition to the trim elements described in FIG. 7, a frame section is added around the window glass. The fastening of the window glass to the system is illustrated by the inset in FIG. 7-A.

[0033]FIG. 8 shows a base mold 200 that can be applied on or attached to inside wall 12, thus, simplifying the run of electric for structure 10. In one embodiment, base mold 200 consist of two pieces a surface mount wall piece 202 and a decorative outer piece 204 that snap on, or is other wise attached, after wall piece 202 is installed or attached, such as by fastening members, such as screws 208. Though not preferred, base mold 200 can also be one piece and attached to wall 12 through adhesives, caulks, etc. Base mold 200 requires no outside fastening and the electric is built into it to simplify the process of electrifying the inside, which provides certain advantages, especially where structure 10 is used as an office trailer. Wires 210 (i.e. black, red and green)can act as a pre-wired, and can be protected with a GFI at the beginning of the run.

[0034]FIG. 9 shows how the corners of the pre-wired baseboard 200 are formed. To install, the wire is stripped back, preferably with a metal blade. A 45° angle at the end of mold 200 is preferably cut with metal shears or other hand tool, so that the ends of adjacent molds 200 abut to form the corner, when pieces 204 are snapped on to corresponding wall pieces 202. Wires 210 are protected inside the interior of metal baseboard 200 by providing the equivalent of a junction box and can be connected together by caps 212.

[0035] Baseboard/mold 200 can also house coaxial cable, computer cable, phone lines, etc. Base mold 200 can be manufactured in long lengths and is preferably extruded aluminum. Any molding on the top edge of walls 12 and 14, can be decorative only and provided in many different forms.

[0036]FIG. 10 shows structure 10 used in a commercial application where electrical conduit 300 might be required. Provisions for conduit 300 can be accomplished with system 10 preferably at a corner 100, by providing two holes 302 and 304 on inner corner piece 101 and/or by sliding conduit 300 down through holes 36 in walls 12 and/or 14. Hooking up an electrical conduit 300 at a hole that has been made on the inside to accept a junction box can all be accomplished without damaging or modifying the outside of structure 10. Once conduit 300 is installed, outside corner piece 102 would be placed over and attached as described above.

[0037]FIG. 11 illustrates one embodiment whereby the system attaches to a conventional roof. FIG. 12 illustrates an embodiment whereby the system attaches to a foundation. As shown, above the foundation are a foundation gasket and a bottom piece which comprises a portion that makes a 45 degree angle away from the foundation on the outer portion of the structure.

[0038] The various components of the present invention are not limited to any specific dimensions. Furthermore, though it is preferred that the walls 12 and 14 be constructed from a metal material, such as aluminum, such is not limiting, and other materials can be used and all are considered within the scope of the present invention.

[0039] System 10 also differs from other metal buildings in that the outside surface has a flat configuration making repair a relatively easy task of just placing a flat piece of aluminum or steel as the case may be, over the damaged area and caulking it.

[0040] The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious modifications will occur to a person skilled in the art. 

What I claim is:
 1. A metal structural system, comprising: a plurality of inner wall elements (“IWEs”); a plurality of outer wall elements (“OWEs”); wherein IWEs and OWEs are attached together to define a hollow space therebetween which is adapted for receipt of insulation therein through injection techniques.
 2. The system of claim 1, further comprising a joint, said joint comprising: a u-shaped stud like element (“SLE”) attached integral to either a first end of said IWE or a first end of said OWE, said SLE separating an IWE from an attached OWE to define a hollow space.
 3. The system of claim 2, further comprising: a first gasket disposed between the SLE and the IWE; a second gasket disposed between the SLE and the OWE.
 4. The system of claim 2, further comprising: fastening devices for connecting two or more IWEs; and fastening devices for connecting two or more OWEs.
 5. The system of claim 2, further comprising: fastening devices for connecting one or more IWEs to one or more OWEs.
 6. The system of claim 2, wherein each SLE divides the hollow space into a chamber on each side of said SLE, said SLE having one or more holes for allowing material to flow between said chambers found on either side of the SLE.
 7. The system of claim 2, further comprising one or more corner assemblies, each corner assembly including: an inner corner piece; and an outer corner piece;
 8. The system of claim 7, said corner assembly further comprising: a central outer gasket disposed between said outer corner piece and said inner corner piece; a first peripheral outer gasket disposed between said inner corner piece and a first OWE; and a second peripheral outer gasket disposed between said inner corner piece and a second OWE.
 9. The system of claim 1, further comprising a track like member formed on the top end of the IWE and the OWE; and a top member attached to said track like member.
 10. The system of claim 9, wherein the top member comprises holes for access to the hollow space defined by the IWE and the OWE.
 11. The system of claim 10, further comprising means for plugging the holes.
 12. The system of claim 1, wherein the IWE and the OWE are constructed similar to each other.
 13. The system of claim 1, further comprising: one or more trim elements, wherein an inner section of the trim is slid into a hole in the IWE and the outer section of the trim element is slid into a hole in the OWE.
 14. The system of claim 1, further comprising a base mold attachable to the IWE.
 15. The system of claim 14, wherein the base mold comprises a surface wall mount attached to the IWE and an outer piece attached to the surface wall mount.
 16. The system of claim 1, further comprising: a bottom piece with an approximately 45 degree angle flange away from a foundation for the system attached to the bottom of an IWE and an OWE; and a bottom gasket disposed between said bottom piece and the foundation.
 17. A refrigerated box, comprising: a plurality of inner wall elements (“IWEs”); a plurality of outer wall elements (“OWEs”); wherein IWEs and OWEs are attached together to define a hollow space therebetween which is adapted for receipt of insulation therein through injection techniques.
 18. A metal structural system, comprising: a plurality of inner wall elements (“IWEs”); a plurality of outer wall elements (“OWEs”); a joint, comprising a u-shaped stud like element (“SLE”) attached integral to either a first end of said IWE or a first end of said OWE, said SLE separating an IWE from an attached OWE to define a hollow space, wherein each SLE divides the hollow space into a chamber on each side of said SLE, said SLE having one or more holes for allowing material to flow between said chambers found on either side of the SLE; and one or more corner assemblies, each corner assembly including: an inner corner piece; and an outer corner piece. 